LEMON Manuals: Even more car manuals for everyone
Home >> Volkswagen >> 2018 >> Beetle S, 2D Hatchback >> Repair and Diagnosis >> External Pages >> Different car >> Section 111 (Gears, Shafts - Manual Transmission 02Q (Convertible)) >> 35 Gears, Shafts >> Description And Operation >> Output Shaft, 1st To 4th Gears Overview

Output Shaft, 1st To 4th Gears Overview

WARNING: This page is about a different car, the 2016 Volkswagen Beetle, 2015 Volkswagen Beetle, 2014 Volkswagen Beetle, and 2013 Volkswagen Beetle. However, it is still accessible from the selected car via links, so may be relevant.

Special tools and workshop equipment required 

NOTE:

Warm the bearing inner race/tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) using the Inductive Heat Unit VAS 6414. Wear protective gloves.

Replace both tapered roller bearings together.

Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to OUTPUT SHAFT, 1ST TO 4TH GEARS, ADJUSTING .

Fig 1: Exploded View Of Output Shaft, 1st To 4th Gears Components
GWWM35-10000Courtesy of VOLKSWAGEN GROUP OF AMERICA, INC.
  1. Clutch Housing
  2. Oil Deflector Ring
  3. Dished Washer
  4. Outer Race/Tapered Roller Bearing
  5. Bearing Inner Race/Taper Roller Bearing
  6. Output Shaft
  7. Needle Bearing
    • For 2nd gear.
  8. 2nd Gear
  9. 2nd Gear Inner Race
    • Replace if there are wear grooves.
    • Installed position, refer to Figure.
  10. 2nd Gear Outer race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installed position, refer to Figure.
  11. 2nd Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear.
    • Installed position, refer to Figure.
  12. Locking Collar with Synchronizer Hub for 1st and 2nd Gears
    • After removing the locking ring -item 13-, remove the 2nd gear. Refer to Figure.
    • Disassembling, refer to Figure.
    • Assembling the locking collar/synchronizer hub, refer to Figure and toFigure.
    • Installed position, refer to Figure.
    • Installing, refer to Figure.
  13. Locking Ring
  14. 1st Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear.
    • Installed position, refer to Figure.
  15. 1st Gear Outer Race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installed position, refer to Figure.
  16. 1st Gear Inner Race
    • Replace if there are wear grooves.
    • Installed position, refer to Figure.
  17. Needle Bearing
    • For 1st gear.
  18. 1st Gear
    • Mount on the output shaft, refer to Figure.
  19. Thrust Washer
    • For 1st and 4th gears.
    • Quantity: 2
    • The tab on the thrust washer must fit into the hole in the output shaft.
  20. Washer
    • Holds the thrust washers -item 19- in place on the output shaft.
  21. Needle Bearing
    • For 4th gear.
  22. 4th Gear
  23. 4th Gear Synchronizer Ring
    • Made from brass or steel.
    • Checking for wear, refer to Figure.
  24. Locking Collar with Synchronizer Hub for 3rd and 4th Gears
    • After removing the locking ring -item 25-, remove the 4th gear. Refer to Figure.
    • Disassembling, refer to Figure.
    • Assembling the locking collar/synchronizer hub, refer to Figure and toFigure.
    • Installed position: locking collar/synchronizer hub, refer to Figure.
    • Installing, refer to Figure.
  25. Locking Ring
  26. 3rd Gear Synchronizer Ring
    • Check the inner running surface for grooves and radial wear.
    • Installed position, refer to Figure.
  27. 3rd Gear Outer Race
    • Check the inner friction surface for wear. Refer to Figure.
    • Check the outer friction surface for wear. Refer to Figure.
    • Installed position, refer to Figure.
  28. 3rd Gear Inner Race
    • Replace if there are wear grooves.
    • Installed position, refer to Figure.
  29. Needle Bearing
    • For 3rd gear.
  30. 3rd Gear
    • Mount on the output shaft, refer to Figure.
  31. Bearing Inner Race/Tapered Roller Bearing
  32. Locking Ring
    • Select the correct one when replacing the tapered roller bearing -item 31- and the output shaft -item 6-. Refer to Figure.
  33. Outer Race/Tapered Roller Bearing
  34. Adjusting Shim
  35. Transmission Housing
scientia non olet · About LEMON Manuals